Unplanned downtime caused by equipment failure can be extremely expensive in terms of lost production, lost revenue, spare parts, repair labor etc. For this reason, there is a great deal of industry focus now on an approach called Predictive Maintenance (PdM).
The concept is simple: A failing motor will always draw more power for a period before it fails completely. The idea is to monitor the current draw of the motor, and track it in real time. Moreover, by setting an ALERT 5-10% above or below the ‘normal’ power draw range, the motor will provide early warning of developing problems in time to fix them before disaster strikes.
Examples of potential failure include
- Over-loaded motors caused by
- Overheating due to torque overload; failure of rotor, bearing, windings insulation
- Phase imbalance
- Capacitor failure
- Clogged downstream filters
- Under-loaded motors caused by
- Broken or slipping drive belt
- Loose or sheared shaft coupling
- Open pump discharge
- Restricted pump intake
- Clogged intake filters or screens
And as a bonus, you can actually reduce maintenance costs at the same time: Rather than relying solely on a time-based maintenance schedule, maintenance can be scheduled when it is more convenient and cost-effective.
Equipment Failure Alert
- Observation: At 04:50 in the morning the Purified Water Circulation Pump Tripped, dropping the power consumed by the system below the configured Alert Level.
- Action: The Alert level triggered an automatic email to be sent, as well as SMS text message.